Radiant heating unit including a laminated radiant heating panel



Oct. 23, 1962 A. A. HORNER 3,060,300

RADIANT HEATING UNIT mcwomc A LAMINATED RADIANT HEATING PANEL Filed Dec. 2, 1958 2 Sheets-Sheet 1 INVENTOR ALBERT A. HORNE]? BY @1452 4 W ATTORNEYS A. A. HORNER Oct. 23, 1962 RADIANT HEATING UNIT INCLUDING A LAMINATED RADIANT HEATING PANEL Filed Dec. 2, 1958 2 Sheets-Sheet 2 FIG.

INVENTOR ALBERT A. HORNE/i ATTORNEY! Unite rats This invention relates to 'a radiant heating unit. More specifically, this invention relates to a radiant heating unit having insulation means and an inexpensive housing by which it is adapted to be mounted on a ceiling or wall. Theinvention also relates to a radiant heating panel safety lamination and a process for making it by which the possibility of the dangerous shattering of the glass heating plate is eliminated.

It is an object of this invention to provide a radiant heating unit of inexpensive yet durable nature in which ample means are provided to insulate the heating panel to preclude the marring or damaging of the adjoining Woodwork.

It is a further object of this invention to provide, for a radiant heating panel, a simplified housing construction whereby replacement of the panel is possible with great ease and without the need for special tools or knowledge.

It is a further object of this invention to provide in a radiant heating unit a housing and panel unit which increase the radiance and reduce the convection loss of the heat generated by the heating plate.

It is a further object of this invention to provide in an electric radiant heating panels a safety lamination and process for making it whereby the possibility of dangerous shattering of the glass heating plate is eliminated and at the same time there is no need for a guard or grille over the plate.

It is a further object of this invention to provide, in a radiant heating unit, means to reduce the possibility of corrosion or of electrical and thermal shock to the heater plate and hence to increase its life.

This invention embodies other novel features, details of construction and arrangement of parts which are hereinafter set forth in the specification and claims and illustrated in the accompanying drawings wherein:

FIG. 1 is a perspective view of a heating unit embodying the invention as installed on a ceiling;

FIG. 2 is a perspective view of a heating unit embodying the invention as installed on a wall;

FIG. 3 is an exploded view showing a preferred embodiment of the invention;

FIG. 4 is an enlarged sectional view taken on the line 4--4 of FIG. 3;

FIG. 5 is an exploded view of a heating unit embodying a modified form of the invention;

FIG. 6 is an enlarged sectional view taken on the line 66 of FIG. 5;

FIG. 7 is a perspective view of the heating panel laminate or unit with the housing removed;

FIG. 8 is a perspective view of the heating panel laminate or unit comprising a preferred embodiment of the invention with part of the lamination broken away to show its structure;

FIG. 9 is a greatly enlarged fragmentary sectional view taken on the line 9 -9 of FIG. 8; and

FIGS. 10 through 13 are fragmentary sectional views showing modified forms of the heating panel unit of the invention.

Referring more specifically to the drawings, a heating unit comprising the preferred embodiment of the invention is shown in FIG. 3 and generally designated 10. It comprises a heating panel unit or laminate 12, spacing means 14, and insulation means 16. These parts are stacked as shown in FIG. 4 and enclosedin a rectangular frame 18. The heating unit may be affixed to a ceiling 3,650,300 Patented Oct. 23., 1952 ice members 26 for the electric coating. Electric leads 28' extend from the connection members through an aperture 30 in the insulation means 16 to a quick-detachable plug (not shown) communicating with an appropriate power source. The upper or back surface of the glass plate 22 has applied thereto over the coating 24 a thickness of an insulating and corrosion-preventing adhesive 32. The adhesive is liberally applied about terminal connection members 26 to encapsulate them in moistureimpervious fashion and to thereby preclude the possibility of accidental short circuiting or arcing thereof. The adhesive securely holds :a layer of heat resisting material 34, to the back or upper surface of the glass panel so that the breaking of the glass plate 22 will be rendered harmless by the holding of the broken fragments by the heat-resisting material layer. As will be understood, a patch of the layer 34 is removed to provide access to the terminal connection members 26.

Centering the panel unit in its enclosing frame and comprising part of the spacing means 14 are four ceramic corner spacers 36. Each spacer is L-shaped and is undercut as at 38 to provide notches receiving the corners.

respectively of the panel unit 12. A layer 40 of silicone rubber may be inserted in the undercut area to provide an insulating cushion for the top or back surface of the panel unit. As shown in FIG. 3, other spacer means comprise rectangular ceramic blocks 42 disposed preferably along the center line of the panel unit 12. The spacer means together assure an insulating air space be tween the top or back surface of the panel unit and the insulation means.

The insulation means 16 comprises a mat 44 or block of fibrous insulation material such as glass fiber board, Marinite, or Thermobestos (the last two being products of IohnsManville, Inc). Sandwiching the insulation mat 44 on both the top and bottom are co-extensive sheets 46 and 48 of aluminum or the like each adapted to serve as a protector of the insulation and as reflective means to throw back radiant and/or convective heat which otherwise would be wasted. The top sheet 46 of aluminum is preferably somewhat thicker than the other to serve as the back of the heating unit housing.

The rectangular frame 18 for the preferred embodiment of the invention shown in FIG. 3 may comprise a single length of channel extrusion of aluminum or the like notched and bent at right angles at corners to form the rectangular shape shown. The final corner may be held in position by two or more self-tapping screws 50. Ventilation through the heating unit is permitted by a plurality of holes 52 which may be evenly spaced along the side of the frame 18 immediately above the panel unit 12.

A modified form of the invention is shown in FIGS. 5 and 6 and generally designated Parts of the modified form of the invention shown in FIGS. 5 and 6 are designated by the primed form of the numeral designating similar parts of the preferred embodiment of the invention shown in FIGS. 3 and 4. The modification is similar to the preferred embodiment with the exception that the rectangular frame 18 and backing sheet 46 of the preferred embodiment are replaced by a formed housing wrapper 112 of inverted channel shape with flanges 114 directed inward from the opposite outer edges thereof. Into this housing wrapper may be slid the panel unit 12", the spacing means 14' and insulation means 16 of the modified heating unit. End members 116 of the modified form of housing may comprise lengths of channelshaped members with notches 118 at opposite ends thereof to receive the ends of the flanges 114 of the housing sheet. The four corners of the structure in this modified embodiment may have holes therethrough to receive an choring bolts 20' for installation.

Heating Panel Safely Lamination and Process for Making It The fact that the panel unit 12 or 12 of FIGS. 1 through 6 embodies a safety lamination to prevent falling or dangerous shattering of the glass has already been mentioned. This portion of the invention presents a novelty not only in the lamination, but in the process for making it. The product of this part of the invention includes a glass heating plate which has a heat-resisting layer adhesively secured to the back surface thereof so that if the glass plate breaks, fragments will not fall but the layer will hold them safely in position until such time as the panel can be replaced.

For clarity in the specific description herebelow and in FIGS. 7 through 13, new numerals are assigned to the specific layers of the panel unit. The numerals applied to the parts of panel unit hereabove referred to them only generally. It should be understood, however, that the panel units 200 through 200"" are forms of the panel units 12 and 12 of FIGS. 1 through 6.

The preferred heating panel of the invention and modified forms thereof are pictured apart from the heating unit housing in FIGS. 7 through 13. The preferred panel is generally designated 200 and is shown in the sectional view of FIG. 9. An idea of the specific structure of the preferred laminated panel unit of the invention can be gained from a description of the process of making it and a description of the composition of the various lamina. To the conventional glass heating plate 202 having a resistance coating 204 thereon is applied a primer such as the Dow Corning A-4094 primer which facilitates the adhesion of the preferred adhesive substance. After the primer has air dried for a prescribed amount of time, say minutes, the surface is then coated with a .010-.030 inch layer of the adhesive 206. A preferred adhesive is Silastic RTV 501 with catalyst A. (Silastic is a Dow Corning silicone which vulcanizes to form a rubber-like product.) Immediately, the heat-resisting layer comprising a pure glass fiber cloth 208, free of sizing and .010 to .030 inch in thickness, is applied over the adhesive and set in place with a damp rubber or glass roller or squeegee, assuring that the adhesive has filled the interstices of the cloth. Vulcanization is accomplished within 24 hours and the product is completely cured at room temperature in 4 to 7 days.

For the adhesive layer 206 other adhesives such as Pliobond (a product of Goodyear Tire and Rubber Company), Butacite (a product of Dupont), and silicon-e varnish have been used. The vulcanization of Silastic produces the preferred adhesive bond, however. Similarly, for the heat-resisting layer glass fiber cloth is preferred over asbestos cloth and others. The embodiment of the lamination described above and including the Silastic and the glass fiber fabric is preferred over pressure sensitive insulation tapes with backing sheets of material such as silicone, Teflon (Dupont) or Micabond (Continental- Diamond Fiber Co.). Such tapes may be adhered directly to the glass heating plate and will to some extent keep the glass from shattering harmfully.

A slight variation in producing a preferred structure involves spraying or brushing Dow Corning A4094 Primer on the plate 202 and permitting it to air dry for, say, 30 minutes. The glass fiber cloth is then smoothed. in position on the plate. Thereafter, over the cloth a .010 to .030 inch coating of Silastic RTV without Catalyst A is applied with a rubber or glass roller. This assures that the interstices of the cloth are filled. An alternate catalyst such as Nuodex Silicure T-773, manufactured by the Heyden Newport Chemical Corporation, Elizabeth, New Jersey, is then sprayed on. The latter catalyst will make it possible to accomplish most of the vulcanization in not more than 15 minutes.

In the modifications of the preferred panel unit shown in FIGS. 10 through 13 an additional backing layer of protective or insulating material is mounted against or suitably attached to the back of the heat-resisting material; the parts or units are designated by the primed, double primed, triple primed, or quadruple primed form of the numeral designating similar and corresponding parts shown in the FIG. 9 representation of the preferred embodiment.

A modified embodiment of the panel unit of the invention is shown in FIG. 10 wherein over the insulating cloth 208' such as glass fiber cloth, an additional layer 210 of adhesive holds a metal sheet 212 preferably of aluminum. This metal not only protects the laminate from above but also serves as a reflector to throwback some heat which would otherwise be wasted.

FIG. 11 shows another embodiment of the panel unit of the invention. In this form of the invention a layer 214 of adhesive holds to the glass fiber fabric a thickness 216 of insulation board. The insulation board may comprise glass fiber board, Marinite, or Thermobestos (the latter two being products of Johns-Manville, Inc.).

In the embodiment of the invention shown in FIG. 12 a layer 218 of adhesive secures a thickness of insulation board 220 to the preferred laminate of FIG. 9. To the top of the insulation board is secured by adhesive 222 a sheet 224 of metal backing adapted to both protect the panel unit and reflect back what would otherwise be wasted heat.

A still further embodiment of the invention is shown in FIG. 13 in which a layer of adhesive 206"" secures a thickness 226 of insulation board directly to the glass plate.

The safety lamination of the invention eliminates a danger inherent in the glass heating panels of the prior art; namely, the harmful shattering or breaking of the glass panel. The backing for the glass plate in all embodiments of the invention is of insulating nature and not only protects the surrounding area from the large amount of heat produced but also reduces possibility of electrical short circuit or shock. The novel method for producing the lamination has been found both effective and inexpensive.

While this invention has been shown in but a limited number of forms, it is obvious to those skilled in the art that it is not so limited but is susceptible of various other changes and modifications without departing from the spirit and scope of the claimed invention.

I claim:

1. A radiant space heating safety lamination comprising, a glass plate having a heat-producing coating on the back thereof, a layer of adhesive securing to the back of said glass plate over said heat-producing coating a layer of glass fiber fabric, said glass fiber fabric being substantially coextensive with said glass plate, and a second layer of adhesive securing to the back of said fabric a metal sheet, whereby the glass fiber fabric will prevent the glass plate from shattering if it should break.

2. A radiant space heating safety lamination comprising, a glass plate having a heat-producing coating on the back thereof, a layer of adhesive securing to the back of said glass plate over said heat-producing coating a layer of glass fiber fabric, said glass fiber fabric being substantially coextensive with said glass plate, and a second layer of adhesive securing to the back of said fabric a layer of insulation board, whereby the glass fiber fabric will prevent the glass plate from shattering if it should break.

3. A radiant space heating safety lamination as described in claim 2 wherein a third layer of adhesive secures a metal plate to the back of said insulation board.

4. A radiant space heating safety lamination comprising, a glass plate having a heat-producing coating on the back thereof, a layer of adhesive securing to the back of said glass plate over said heat-producing coating a first layer of heat-resisting material, said first layer being substantially coextensive with said glass plate, and a second layer of protective backing material attached to the back of said heat-resisting material and in substantial coextensive contact therewith for protecting said heat-resisting material, whereby the heat-resisting material will prevent the glass plate from shattering if it should break.

5. A radiant space heating safety lamination according to claim 4 wherein said heat-resisting material comprises a thickness of insulating fabric.

6. A radiant space heating safety lamination according to claim 4 wherein said heat-resisting material comprises a layer of glass fiber fabric.

7. A radiant space heater comprising an open frame member, a glass plate having a heat-producing coating on the back thereof supported in said frame member, a layer of adhesive securing to the back of said glass plate over said heat-producing coating a first layer of heat-resisting material, said first layer being substantially coextensive with said glass plate, and a second layer of backing material mounted against the back of said heat-resisting material and in substantial coextensive contact therewith for protecting said heat-resisting material, whereby the heatresisting material will prevent the glass plate from shattering if it should break.

8. A radiant space heater according to claim 7 wherein said second layer of backing material comprises a sheet of metal.

9. A radiant space heater according to claim 7 wherein said second layer of backing material comprises a layer of insulating material.

10. A radiant space heater according to claim 7 wherein said second layer of backing material comprises a layer of fiber glass material.

1 1. A radiant space heater according to claim 9 further defined by a sheet of metal in substantial coextensive contact with the back of the second layer of insulating material.

12. A radiant space heater comprising a plurality of U-shaped structural members forming an open rectangular frame, the web portion of said U-shaped members forming the sidewalls of said frame and the legs of said U-shaped members extending inwardly and forming spaced-apart outer and inner flange portions, a glass plate supported in said frame against the outer flange portion thereof and having a heat-producing coating on the back thereof; a shatterproofing laminate secured to the back of said glass plate over said heat-producing coating, said shatterproofing laminate being substantially coextensive with said glass plate and comprising a layer of adhesive over said heat-producing coating and a layer of heatresisting material; an insulation laminate supported in said frame in a plane parallel with said shatterproofing laminate and spaced-apart therefrom by a spacer at each corner of said frame, said insulation laminate being substantially coextensive with said glass plate and comprising a sheet of insulating board sandwiched by two sheets of metal; said spacers, said insulation laminate, and the flange portions of said frame having aligned apertures adapted to receive elongated fastening means for assembling said radiant space heater.

References Cited in the tile of this patent UNITED STATES PATENTS 1,228,165 Bardin May 29, 1917 2,397,141 Holtje Mar. 26, 1946 2,526,728 Burk Oct. 24, 1950 2,553,974 Lamb May 22, 1951 2,601,337 Johannsen June 24, 1952 2,640,904 Gaiser June 2, 1953 2,730,598 Lytle Jan. 10, 1956 2,754,237 Brooks July 10, 1956 2,761,945 Colbert et al Sept. 4, 1956 2,770,704 Razlag Nov. 13, 1956 2,780,708 Glynn et al. Feb. 5, 1957 2,781,440 Petersen et al Feb. 12, 1957 2,845,527 McEachron July 29, 1958 2,866,881 McMillen Dec. 30, 1958 FOREIGN PATENTS 800,095 Great Britain Aug. 20, 1958 

